Method and apparatus for casting concrete and other settable materials

ABSTRACT

A METHOD AND APPARATUS ARE PROVIDED BY WHICH CONCRETE OR SIMILAR CASTABLE MATERIAL CAN BE FORMED IN A VERTICAL STACK USING A SINGLE FRAME. THE INITIAL SLAB OR FORM IS POURED ONTO A PLATFORM WITH OR WITHOUT RE-ENFORCING STEEL LYING THEREON. WHEN THE INITIAL SLAB HAS BEEN POURED WITHIN THE SURROUNDING FRAME OR MOLD AND AT LEAST PARTIALLY SET, THE FRAME IS ELEVATED A PREDETERMINED DISTANCE, A SUITABLE BOND BREAKING AGENT SUCH AS, FOR EXAMPLE, A CARBOARD SHEET, HAVING THE APPROXIMATE DIMENSIONS OF THE PREVIOUS SLAB, IS PLACED OVER THE TOP OF THE LATTER, RE-ENFORCING STEEL PLACED THEREON AND THE CONCRETE POURING STEP REPEATED. THE FRESHLY POURED CONCRETE IS SMOOTHED OUT BY THE USE OF VIBRATORS, TROWELS AND LEVELING BARS. THE CASTING FRAME MAY BE SO CONSTRUCTED AS TO FORM TWO OR MORE MOLDED FORMS WHILE SAID FRAME IS AT ONE HORIZONTAL POSITION.

Nov. 9, 19 M. E. \IMLE 3,W,Wfl

METHOD AND APPARATUS FOR CASTING CONCRETE AND OTHER SETTABLE MATERIALS Filed March 25, 1969 5 Sheets-Sheet 1 m LOQ' MD cucu Nov. 9, 197 y M. E. VELE 3,618,181

METHOD AND APPARATUS FOR CASTING CONCRETE AND OTHER SETTABLE MATERIALS Filed March 25. 1969 5 Sheets-Sheet 2 PIC-3.2 HQ 3 Nov. 9, 1971 M. E. VIEALE 3,613,131

METHOD AND APPARATUS FOR CASTING CONCRETE AND' OTHER SETTABLE MATERIALS Filed March 25. 1969 5 Sheets-Sheet FIG.4

Nov. 9, 1971 M. E. VEALE 3,618A8fl METHOD AND APPARATUS FOR CASTING CONCRETE AND OTHER SETTABLE MATERIALS Filed March 25, 1969 5 Sheets-Sheet 4.

HOO\ I06 MO 22 23 I08 y Nov. 9, 1971 M. E. VEALE fi w METHOD AND APPARATUS FOR CASTING CONCRETE AND QTHER SETTABLE MATERIALS Filed March 25, 1969 5 Sheets-Sheet 5 US. Cl. 25-41 1K 2 Claims ABSTRACT OF THE DISCLOSURE A method and apparatus are provided by which concrete or similar castable material can be formed in a vertical stack using a single frame. The initial slab or form is poured onto a platform with or without re-'enforcing steel lying thereon. When the initial slab has been poured within the surrounding frame or mold and at least partially set, the frame is elevated a predetermined distance, a suitable bond breaking agent such as, for example, a cardboard sheet, having the approximate dimensions of the previous slab, is placed over the top of the latter, re-enforcing steel placed thereon and the concrete pouring step repeated. The freshly poured concrete is smoothed out by the use of vibrators, trowels and leveling bars. The casting frame may be so constructed as to form two or more molded forms while said frame is at one horizontal position.

The present invention relates to a novel apparatus and method for forming bodies or slabs having a substantially flat and/or patterned surface. More particularly it is concerned with such an apparatus and method for manufacturing shaped bodies from a settable material whereby a series or stack of said bodies can be formed, one on top of the other by the use of a single mold without having to disassemble the mold after a body has been formed and prior to making the succeeding body.

BACKGROUND OF THE INVENTION My invention is directed primarily to the building industry where it is now common practice to use pre-cast sections for walls, roofs, structural supports, parking curbs and the like. These sections for the most part are manufactured in single molds, bolted or otherwise fastened together. To make a large number of any one of the above mentioned items requires a considerable area over which the individual molds are spread. Thus space is ordinarily a limiting factor on the number of these items one can produce in a given period of time. Moreover, much equipment is necessary for manufacturing shaped bodies of the above mentioned type not only requiring a substantial investment but careful maintenance of a large amount of equipment. Also much labor is required by this method of forming these pre-cast bodies because each of the molds must be unbolted, lifted off the formed body and the mold either stored or reassembled for use in manufacturing another body. After the molds have been thus removed the bodies usually are stacked for more efficient handling when shipping. Because of the relatively large area required by this manufacturing procedure, for example in the case of forming pre-cast sections of a Wall or roof, the operation usually is carried out at a location away from the construction site; requiring hauling of the pre-cast sections to the site thus adding considerably to the construction expense.

Other methods have been proposed for preparing precast concrete slabs for walls, roofs, etc. by forming a plurality of such slabs in a stack. However, these methods and the apparatus used therein suffer from many of the disadvantages possessed by procedures and equipment discussed immediately above. Thus in making a stack of 3,bi8,il Patented Nov. 9, I971 these slabs a frame was placed in a horizontal position and the concrete poured in it. A bond breaking agent was then laid over the top of the poured concrete, a second form assembled, laid on top of and aflixed to the first, after which the concrete was poured in the second form and the foregoing procedure repeated as many times as practical. As in the previously described case, many molds are required for large scale operations, likewise requiring high investment costs.

BRIEF DESCRIPTION OF THE INVENTION By the present invention it has now been made possible to increase the daily production rate of such molded slabs or bodies by the use of a single piece of apparatus that can be readily assembled at the construction site, disassembled when finished and easily transported to the next point of use. Briefly, I manufacture these shaped bodies by pouring a settable material in a shaped, essentially horizontal mold, having neither a top nor a bottom, i.e., a frame, and allowing such material to gain some set strength. Usually, this occurs during the step of leveling or smoothing the upper surface of the freshly poured body and hence no unnecessary waiting period is required. Thereafter a suitable bond breaking agent such as, for example, a heavy cardboard sheet preferably having waxed or equivalent surfaces to avoid adherence to the set material of the first body as well as to the bottom of the succeeding body, is placed over the top of the previously formed slab. The frame is next lifted a vertical distance corresponding to about the thickness of the first body, leaving the sides of the latter still supported by the lower portions of the sides and ends of the casting frame. The previously formed body serves as a platform for the succeeding slab to be formed from the settable material, all as described above. In this connection and as a precaution in preventing. settable ma' terial from adhering to the inner surfaces of the casting frame such surfaces may be coated with a suitable petroleum wax or oil prior to the forming of each slab.

The casting procedure may be repeated as many times as considered practical. In many cases I have prepared double stacks each containing ten concrete slabs, 4 inches thick. After the tenth slab in each stack is formed, the frame is lifted off and re-located. The stacks of slabs-in some cases having dimensions of about 13 feet by 4 /2 feet by 4 inches and weighing approximately 3500 poundscan be lifted by means of a fork truck or crane, placed on a truck for transporting or carried to an adjacent work site.

DESCRIPTION OF THE DRAWINGS The present invention will be further illustrated by reference to the accompanying drawings wherein,

FIG. 1 is an isometric view of the slab casting device of my invention illustrating the formation of a new concrete slab while resting on a stack of previously prepared concrete forms.

FIG. 2 is a broken perspective end view of the casting device showing in some detail one of the four hydraulic power assemblies affixed to each of the four corners of said device.

FIG. 3 is a broken perspective side view of the hydraulic jack shown in FIG. 2 illustrating a further detail of the manner in which it is affixed to the end and side of the casting frame.

FIG. 4 is an end elevational view partially broken away showing the position of the casting device with respect to the last formed slab just prior to elevating said device to receive settable material for the next slab or form.

FIG. 5 is a further detailed broken perspective view of a jack pole and jack rod-cross head assembly illustrating the mechanism by which the jack rods are elevated, the

3 cross head being in an elevated position relative to the power cylinder as is the case when the casting frame is being raised.

FIG. 6 is a broken perspective view of a stack of concrete slabs formed in accordance with the method and apparatus of my invention wherein such slabs have a beveled or chamfered lower side edge.

FIG. 7 is a plan schematic view showing the hydraulic pressure system for the individual jacks used to raise and lower the casting frame.

FIG. 8 is a broken view, partly in section, showing a mold with a plastic sheet as a bond breaking agent suitable for casting forms with a patterned surface.

FIG. 9 is a broken view, partly in section, showing a concrete form having a patterned surface.

FIG. 10 is a perspective view of a pre-formed bond breaking sheet suitable for separating and imparting a patterned surface to successively cast slabs.

In FIG. 1 the casting device of my invention is indicated generally at 10 with ends 12 and 14 along with sides 16 and 18 forming a rectangular frame. The sides, ends, bracing and other structural members may be made of carbon steel 4 inch to about /3 inch in thickness. At each corner of the frame are jack assemblies 20, '22, 23 and 24 comprising a jack pole 26 with holes 28 extending through the pole. At the top of pole 26 is a hydraulic cylinder shown generally at 30. On either side of pole 26 are jack rods 32 and 34 with holes 36 positioned such that when the frame is set to receive a batch of concrete, holes 28 of the jack pole are on a line running half way between adjacent holes 36 on the jack rods. Each of the jacks poles is equipped at the base with leveling screws 38, 40 and 42. Jack rods 32 and 34 are conencted at the top by a cross head 44. The entire frame is braced and made more rigid by means of angle supports 46, 48, 50, 52, 54 and 56. Additional longitudinal support is given the frame on the sides by means of work platform 58. A similar structure, not shown, is afiixed on the exterior of side 16. The frame as shown is bisected by tapered divider beam 60 which is wider at the top than at the base in order to facilitate the upward movement of the casting frame in preparing for the pouring of a subsequent form. Casting device 10 extends around freshly cast slab 63 and over the last cast concrete slab covered by waxed cardboard sheet 62. Slab 63 is partially broken away exposing re-enforcing rods 64. Both the re-enforcing rods and chamfer strips 66 (as shown in FIG. 6) rest on heavy waxed cardboard sheet 62 which in turn is in contact with the previous cast slab constituting the uppermost of the stack of partially set slabs 68 all of which are supported by concrete blocks 67. As casting device moves upwardly with the formation of another slab, wooden chamfer strips 66 become exposed and can be removed leaving a beveled edge 69 which serves to facilitate the lifting of the entire stack of slabs if desired with a fork truck or similar equipment. At each end of the frame are overflow baffle plates 70 and 72 which act to retain freshly poured concrete, for example, from a mixer until it can be evenly distributed within the mold or frame. Generally, it is preferred that the sides and ends of the casting frame are sufficiently high to permit casting of two sets of slabs, as shown for example in FIG. 4, before it is required to elevate the frame for the formation of a subsequent slab.

In FIGS. 2. and 3 jack pole 26-as is the case in jack assemblies 22, 23 and 24is held firmly but in reciprocating relationship with support collars 80 and 82. Collar 80 is affixed to end 14 by means of bolted plate 84 which is an extension of collar 80. Collar 82 like collar 80 is slidable along pole 26 and, as in the case of collar 80, is similarly affixed to end 14 and side 18 by means of bolted plate 85. Collar 82 on opposite sides has arms 86 and 88. Holes in these arms are brought in to register with holes 36 in rods 32 and 34 and held at that level by L-pins 90. Support while the casting frame is in a stationary position is also furnished by T-pin 92 inserted into a hole 28 4 of jack pole 26. At the top of jack pole 26 is hydraulic cylinder 30 equipped with a rod and piston (not shown). Power fluid for operating the cylinder is introduced therein via pressure hose 94 and removed from the top of cylinder 30 through tube 96 and pressure hose 98.

FIG. 4 is a partly broken away elevational end view of casting device 10 illustrating the dual mold embodiment of my invention using a tapered beam and demonstrating the manner in which the latter fits in the inner sides of the cast slabs. Typically this beam may be 3% inches at the top and 3 inches at the base thereby facilitating upward movement of the casting frame after the slab has been poured and begun to set. Slab 63a which is partially set serves as the platform or base on which freshly poured slab 63 rests. It will of course be appreciated that my invention also contemplates embodiments in which only a silngle stack of slabs is formed using a single casting frame having no divider beam.

A schematic view of the hydraulic system employed to raise and lower the casting frame is shown in FIG. 7 wherein pressure to the system is generated by means of pump 100. System pressure is distributed through manifold 102. Jack assemblies 20, 22, 23 and 24 are served by pressure hoses 94 and 98, 104 and 106, 108 and 110, and 112 and 114, respectively.

Operation of the casting device of my invention may be further illustrated by reference to the drawings, particularly FIGS. 1, 5, 6 and 7. The dual mold as shown in FIG. 1 is held at a given level by means of collars and 82 afiixed to end plate 14 and side 18 through the use of bolted plates 84 and 85, respectively. Similar structural means are provided as supporting members for the frame at the other three corners thereof. Initially a cavity is formed by placing concrete blocks 67 in the shape, for example, of a rectangle, the outer dimensions of which coincide with slabs 68. The cavity is filled with sand up to the top of blocks 67 and smoothed. Next, heavy waxed cardboard sheets 62 fitting flush with the outer edges of said rectangular form and extending under beam 60 are placed on top of the sand platform. The framework of my casting device is then lowered by means of hydraulic power over the rectangular form defined by blocks 67 so that the top of beam 60 is about 8 inches above the cardboard sheets. Three cornered wooden chamfer strips 66 running the full length of cardboard sheets 62 are placed along the inside edges of sides 16 and 18 and on either side of beam 60 after which they are stapled or otherwise affixed to cardboard sheets 62. Onto each of the cardboard sheets is then placed a set of reenforcing rods 64. When the rods are in position, suflicient concrete is poured into each form to produce a slab approximately 13 x 4'-6" x 4". The fresh concrete is made to settle rapidly by the use of vibrators and/or by striking work bench 58. A still smoother surface can be obtained by the use of a trowel or leveling bars. After smoothing the upper surface of the first set of slabs, covering them with cardboard and afiixing chamfer strips thereto as previously described, the frame of device 10 is raised through the use of hydraulic power by forcing a suitable liquid, using pump 100, through manifold -102 and then through power lines 94, 104, 108 and 112 to cylinders 30 in jack assemblies 20, 22, 23 and 24, respectively. In each of cylinders 30 is a piston (not shown) 2 /2 inches in diameter aflixed to a rod 43, shown in extended or lifting position in FIG. 5. Pressures of 400 to 600 p.s.i. in the power lines are sufiicient when acting against the bottom area of said pistons to elevate the mold frame. This force transmitted through rods 43 against cross heads 44 with pins and 92 removed permits the entire framework to be raised. The height the frame is raised corresponds to the distance between adjacent holes 28 in poles 26 and adjacent holes 36 in jack rods 32 and 34. In the raising operation when the holes in arms 86 and 88 come into register with holes 36 of jack rods 32 and 34 L-pins 90 are inserted and T-pin 92 placed in hole 28 immediately below collar 82 thus distributing the weight of the casting frame on poles 26 of jack assemblies 20, 22, 23 and 24. Pump 100 is then shut off and power oil from each cylinder 30 permitted to drain back into a reservoir (not shown) via drain lines 9 8, 106, 110 and 114. With the casting frame at the new elevated level the casting cycle previously described is repeated.

FIG. 8 illustrates a type of form used in accordance with my invention to produce a cast slab with a patterned surface. Supporting form 120 is shown as plastic, e.g., polyurethane or polystyrene. Form 120 may also be of wood, metal or other material of suitable strength. Overlaying form 120 is a bond breaking agent 122 which in this figure is shown as plastic such as, for example, polyvinyl chloride or cellulose acetate butyrate. Actually, the patterned surface of form 120 may be covered with a petroleum wax or other material which functions to prevent the cast material from adhering to the surface of the mold form. When using the plastic sheet as a bond breaking agent, the sheet which initially is fiat may be laid over the top of wood or plastic form 120 after which sheet 122 is heated to a temperature sufficient to cause it to conform to the irregular surface of form 120. Thereafter, the form thus prepared-in combination with the apparatus of the present invention-is used as the platform on which to pour the first slab. In subsequent operation a bond breaking sheet 122, for example of the type shown in FIG. 10, may be placed over the first slab while the latter is still soft, after which fresh concrete is poured and spread within the frame of device 10, another plastic or equivalent sheet placed over the second newly formed slab and the procedure repeated-all as described aboveto produce a plurality of vertically stacked forms with patterned surfaces similar to slab 124 illustrated in FIG. 9.

While a certain preferred embodiment of my invention has been described it is to be understood that the basic principles thereof are applicable to a wide variety of casting operations that can be conducted in close proximity to the work site and within an area much less than formerly required.

I claim:

1. Apparatus for casting a body of settable material, said apparatus being readily assembled and disassembled and comprising a frame, individual means detachably mounted to said frame for raising and lowering said frame in assembled form and having a combination leveling and lifting device atfixed to the base thereof whereby said frame can be positioned in a horizontal plane, said individual means comprising a central vertical member, a

separate member on either side of said central member and running substantially the length thereof, a cross member at the uppermost end of said central member affixed to the upper ends of said separate members, the assembly of said cross member and separate members being movable in a vertical path relative to said central member, means slideably mounted on said central member adapted to reciprocate along substantially the length of said central member and to permit said frame to rest on said slideably mounted means at a plurality of predetermined elevations, and means in said central member to exert an upward force on said cross member sufficient to lift said frame relative to said central member.

2. Apparatus for casting a body of settable material, said apparatus being readily assembled and disassembled and comprising a frame, individual means detachably mounted to said frame for raising and lowering said frame in assembled form, said individual means comprising a central vertical member, a separate member on either side of said central member and running substantially the length thereof, a cross member at the uppermost end of said central member afiixed to the upper ends of said separate members, the assembly of said cross member and separate members being movable in a vertical path relative to said central member, means slideably mounted on said central member adapted to reciprocate along substantially the length of said central member and to permit said frame to rest on said slideably mounted means at a plurality of predetermined elevations, ports in said slideably mounted means adapted to be placed into registry at a plurality of levels with corresponding ports in said central member and said separate members, and means in said central member to exert an upward force on said cross member suflicient to lift said frame relative to said central member.

References Cited UNITED STATES PATENTS 2,516,318 6/1950 Hawes 25131 EM 2,659,123 11/1953 Georgii et al. 2541.5 E 2,709,291 5/1955 Harkness et al. 249*21 3,495,800 2/1970 Fisher 249-20 ANDREW R. JUHASZ, Primary Examiner J. F. COAN, Assistant Examiner US. Cl. X.R. 

